Heat Sink Welding with Copper Cold Spray for Stronger Joints
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Solution Overview
Problem
Manufacturing heat sink components from a single metal block is challenging due to the difficulty in shaping fin assemblies without weakening the rigidity and strength, and existing methods using multiple workpieces for bases and fins face issues with welding aluminum alloys, which are prone to separation under external forces.
Innovation Solution
A welding method involving rust removal, degreasing, increasing surface roughness, and a supersonic cold spray process with copper grains to enhance the bonding between workpieces, ensuring a strong and durable heat sink component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If heat sink component is manufactured from a single metal block via cutting or drilling, then the fin assembly can be shaped, but the rigidity and strength are weakened
Solution Approach 1:
The heat sink component is divided into separate workpieces (base and fins) that are manufactured independently and then joined through welding, avoiding the need to cut or drill the single metal block while maintaining structural integrity
Solution Approach 2:
Multiple separately manufactured workpieces are combined through welding to form the complete heat sink component, achieving both the desired fin assembly shape and maintaining high strength and rigidity
2Shape
If bases and fins are made respectively from multiple workpieces and welded, then the fin assembly can be shaped easily, but the welded aluminum alloy workpieces are easy to be separated by external force
Solution Approach 1:
Surface treatment (rust removal, degreasing, roughness increasing) and copper supersonic cold spray are performed on the workpiece surfaces before welding to create optimal bonding conditions, ensuring strong welded joints that resist external forces
Solution Approach 2:
Copper grains are sprayed onto the aluminum alloy workpiece surfaces as an intermediary layer that facilitates welding between aluminum workpieces, improving the strength and reliability of the welded joints
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a heat sink component with increased strength and rigidity, capable of withstanding significant pulling forces without separation, thereby enhancing the durability of the welded structure.
Implementation Method 1
performing a supersonic cold spray process of copper grains to the first surface and the second surface
Implementation Method 2
combining the first surface and the second surface via welding
Data Source
AI summary
A welding method for manufacturing a heat sink has the following steps in sequence: removing rust from a first workpiece and a second workpiece, degreasing the first workpiece and the second workpiece, increasing surface roughness of the first workpiece and the second workpiece, performing a copper supersonic cold spray step to the first workpiece and the second workpiece, and then combining the first workpiece and the second workpiece via welding. With the copper supersonic cold spray step and the surface treatment steps before the copper supersonic cold spray step (i.e. rust removal and degreasing, and surface roughness increasing), the solder can be attached to the workpiece tightly in the combining via welding. Thus, the welded workpieces are combined firmly and not be separated easily. If a heat sink component is made through welding workpieces in the welding method, the heat sink component has higher strength and cannot be destroyed easily.